Continuous Fiber Additive Manufacturing Launch Effects

Continuous Composites Inc. (CCI), in collaboration with Aurora Flight Sciences, plans to design, print, and test launch effect fuselage structures using CF3D® technology. These structures, similar to those in the MENACE program, will be engineered with minimal waste and reduced manufacturing time. Aurora will provide the necessary data for the geometries and develop a test plan to analyze the components' tolerances, quality, and strength. CCI will use CF3D®'s fiber steering and topology optimization to create lighter, high-performance structures, informed by finite element analysis (FEA). After initial printing and inspection, CCI will train Aurora engineers on CF3D® design, workflow, and enterprise application. This collaboration will enable Aurora to utilize CF3D® technology to redesign, print, and test a second iteration of a launch effect fuselage. Ultimately, this work will enable Aurora to adopt CF3D® into program of record components production, allowing for rapid prototyping and automated production of various aerospace structures, enhancing design capabilities for future Department of Defense projects.